Composite material with failure detection properties

ABSTRACT

A multiple layer composite material having fluid breach detection features provides indication of a failure in a fluid barrier. The indication of breach of fluid is provided before failure of a final layer of the composite material. The multiple layer composite material includes more than one fluid impermeable layer with an intermediate layer sealed between the fluid impermeable layers. Failure of one of the fluid impermeable layers is detected by fluid contact in the intermediate layer. The intermediate layer includes a reagent and/or detection device to indicate that the fluid has reached the intermediate layer.

BACKGROUND OF THE INVENTION

The present invention relates to a multiple layer composite materialincluding features for detection of a failure in one or more layersresulting in a fluid breach of the composite material. The compositematerial is suitable for use as a barrier in many applications wherefluid penetration is undesired.

Impermeable covers are intended to protect areas, objects, or peoplefrom coming into contact with a fluid. These covers have been made fromflexible fabric with a flexible fluid proof coating such as polyvinylchlorides (“PVCs”) or polyurethanes. Over time, the coatings lose theirability to bar entry of a fluid into the protected area, or ontoprotected objects or people.

These covers are known to fail as barriers in a number of ways. Somefailure modes are obvious, such as large cracks or tears in the cover,or a visible delamination of the coating. Other failure modes are lessobservable. Current methods of inspection of a barrier material forintegrity are reactive and identify a failure only after fluid hasbreached the barrier.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides an improved compositematerial having multiple layers with failure detection features fordetecting breach of fluid into the composite material before the finallayer is breached. Additionally, the composite material is useful in avariety of applications as a barrier material.

One embodiment provides a multiple layer composite material with a firstfluid impermeable layer, a second fluid impermeable layer, and anintermediate layer sealed between the first and second fluid impermeablelayers. The intermediate layer includes a reagent that is reactive whena fluid contacts the reagent after having passed through the first orsecond fluid impermeable layers.

In one aspect, the reagent is visibly detectable when the fluid contactsthe reagent.

In another aspect, conductive elements are in fluid communication withthe reagent. The reagent is a variable conductivity material thatconducts electric current in the electric circuit after contact with thefluid.

In one aspect, the reagent is reactive to a cleaning fluid applied tothe first fluid permeable layer.

In any of the foregoing embodiments, the intermediate layer isimpregnated with a pattern of reagent, and the first fluid impermeablelayer is translucent. The pattern is visible through the first fluidimpermeable layer after the fluid passes through the first fluidimpermeable layer.

In one aspect, the reagent releases a fragrant substance when reactingto the fluid.

In another embodiment, the composite material with breach detectionproperties has a first fluid impermeable layer, a second fluidimpermeable layer, and an intermediate layer sealed between the firstand second fluid impermeable layers. The intermediate layer has aplurality of fibers with an alterable characteristic. The characteristicis alterable after contact with a fluid after the fluid passes throughthe first or second fluid impermeable layer.

In another embodiment, the multiple layer material with breach detectionproperties has a first fluid impermeable layer, a second fluidimpermeable layer, and an intermediate layer sealed between the firstand second fluid impermeable layers. The intermediate layer has adetector that indicates a status of the material.

In another embodiment, the multiple layer material with breach detectionproperties has a first fluid impermeable layer, a second fluidimpermeable layer, and an intermediate layer sealed between the firstand second fluid impermeable layers. Both a positive terminal and anegative terminal are associated with the intermediate layer.

In one aspect, the positive terminal and the negative terminal areconnected to a detector that is operable to determine a status of thematerial.

Any of the foregoing embodiments may provide the composite material as abarrier for a mattress cover, a protective garment, a glove, a raincoat, a handle, a seat, or a pad.

In one embodiment, a method of manufacturing a composite material withbreach detection properties is provided. The method includes the stepsof: providing a first fluid impermeable layer, providing a second fluidimpermeable layer, providing an intermediate layer having a breachdetector therein, and sealing the intermediate layer between the firstand second fluid impermeable layers.

In another embodiment, a method of detecting a breach in a compositematerial is provided. The method comprising the steps of: providing afirst fluid impermeable layer, providing a second fluid impermeablelayer, providing an intermediate layer, providing a breach detectioncomponent in the intermediate layer, sealing the intermediate layerbetween the first and second fluid impermeable layers, and observing achange in the breach detection component after a fluid passes throughthe first impermeable layer.

Further, the above embodiments may include the multiple layer compositematerial having a first outer fluid impermeable layer, a second outerfluid impermeable layer opposite said first outer impermeable layer, aninner fluid impermeable layer having a reagent, and an innerreinforcement layer. The inner fluid impermeable layer and the innerreinforcement layer are sealed between the first outer fluid impermeablelayer and said second outer impermeable layer. The reagent is activewith a fluid when the fluid contacts the reagent after passing throughthe first outer fluid impermeable layer or the second outer fluidimpermeable layer.

These and other objects, advantages, and features of the invention willbe more fully understood and appreciated by reference to the descriptionof the current embodiment and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of a multiple layer composite material;

FIG. 2 is a second schematic diagram of a second embodiment of amultiple layer composite material;

FIG. 3 is a schematic diagram of a mattress and cover of multiple layercomposite material;

FIG. 4 is a schematic plan view of multiple layer composite materialhaving a detection device; and

FIG. 5 is a circuit diagram for a detection device without a switch;

FIG. 6 is a schematic diagram of a three layer composite materialincluding a detection device;

FIG. 7 is a schematic diagram of a four layer composite materialincluding a detection device;

FIG. 8 is a flow diagram including the steps of a method for detecting afluid breach in a multiple layer composite material;

FIG. 9 is a flow diagram including the steps of a second method fordetecting a fluid breach in a multiple layer composite material;

FIG. 10 is a flow diagram including steps of a third method fordetecting a fluid breach in a multiple layer composite material; and

FIG. 11 is a flow diagram including the steps of another method fordetecting a fluid breach in a multiple layer composite material.

Before the embodiments of the invention are explained in detail, it isto be understood that the invention is not limited to the details ofoperation or to the details of construction and the arrangement of thecomponents set forth in the following description or illustrated in thedrawings. The invention may be implemented in various other embodimentsand may be practiced or carried out in alternative ways not expresslydisclosed herein. Also, it is to be understood that the phraseology andterminology used herein are for the purpose of description and shouldnot be regarded as limiting. The use of “including” and “comprising” andvariations thereof is meant to encompass the items listed thereafter andequivalents thereof as well as additional items and equivalents thereof.Further, enumeration may be used in the description of variousembodiments. Unless otherwise expressly stated, the use of enumerationshould not be construed as limiting the invention to any specific orderor number of components. Nor should the use of enumeration be construedas excluding from the scope of the invention any additional steps orcomponents that might be combined with or into the enumerated steps orcomponents.

DESCRIPTION OF THE EMBODIMENTS Composite Material

Referring to FIG. 1, a multiple layer composite material, generallydesignated as 10, is illustrated. The material includes a first fluidimpermeable layer 12, a second fluid impermeable layer 14, and anintermediate layer 16 within an internal space 18 defined by the firstfluid impermeable layer 12 and the second fluid impermeable layer 14.The intermediate layer 16 may be sealed between the first fluidimpermeable layer 12 and the second fluid impermeable layer 14. Theintermediate layer 16 includes a reagent that is active with a fluidwhen the fluid contacts the reagent after passing through the firstfluid impermeable layer 12 or the second fluid impermeable layer 14.

The material 10 provides a fluid barrier between an environment and anarea, object, or person intended to remain void of contact with thefluid. One of the fluid impermeable layers 12, 14 may be a bottom layerin contact with the area, object, or person intended to be separatedfrom the fluid. The other fluid impermeable layer 12, 14 may be a toplayer opposite the bottom layer. A failure in the top layer of thecomposite material provides an opening for fluid to enter the compositematerial. Once the fluid enters the internal space 18 and interacts withthe reagent of the intermediate layer 16, the failure of the topimpermeable layer and breach of fluid into the composite material can bedetected before failure of the bottom layer. In this way, the bottomlayer acts as a final layer of protection preventing fluids to passthrough the composite material and allowing the overall integrity of thebarrier to remain intact. The composite material may then be replaced torestore the failure detection features.

Another embodiment of the multiple layer composite material is shown inFIG. 2. The multiple layer composite material 100 may include a firstouter fluid impermeable layer 120 and a second outer fluid impermeablelayer 140 opposite the first outer impermeable layer 120. An inner layer160 having a reagent and an inner reinforcement layer 170 may bepositioned within the internal space 180 defined by the first outerfluid impermeable layer 120 and the second outer fluid impermeable layer140. The inner layer 160 and the inner reinforcement layer 170 may besealed between the first outer fluid impermeable layer 120 and thesecond outer impermeable layer 140. The reagent can be activated with afluid when the fluid contacts the reagent after passing through thefirst outer fluid impermeable layer 120 or the second outer fluidimpermeable layer 140.

The composite materials are suitable for use in a variety ofapplications where a barrier material is useful or desired. By way ofexample only, the composite materials may be constructed for use as amattress cover, protective garment, glove, rain coat, barrier on ahandle or seat, or a pad for use in fluid barrier applications. Whenused in any application, the multiple layer composite materials 10, 100may be disposable once fluid has been detected as having passed throughthe first fluid impermeable layer 12, 120 or second fluid impermeablelayer 14, 140.

The fluid impermeable layers may be the outermost layers of thecomposite material or may be layers within a construction havingadditional layers. The fluid impermeable layers may be constructed offlexible fabric structure with a flexible fluid proof coating. Forexample, polyvinyl chlorides (“PVC”) or polyurethanes are suitable.Extruded, rolled, dipped polymers, or polymers that are formed intosheets of material, are also suitable for use as the fluid impermeablelayers. The intermediate layer may be constructed of synthetic ornatural fabric, extruded, woven, unwoven, and/or reinforced materials.

As shown in FIG. 3, if the composite material 10, 100 is used as amattress cover, the cover 200 may surround the internal components 210of a mattress M. It may be desirable to protect the internal components210 of the mattress M from fluid contamination in order to avoidspoiling of the internal components 210 and/or to avoid the spread ofpathogens in fluid that could be deposited on the mattress M. The cover200 can be placed on or around the mattress M, and a breach of fluidthrough a fluid impermeable layer of composite material may be detectedand/or avoided by any of the features described herein.

Failures of an impermeable layer resulting in fluid breach into thecomposite material may be directly observed after the fluid passesthrough the impermeable layer and reacts with a reagent. Meanwhile, theopposite impermeable layer may remain intact. Reagents may be selectedfrom materials that exhibit a first color prior to contact with fluidand are capable of exhibiting a second, different color after contactwith the fluid. Either the failed or intact fluid impermeable layer maybe translucent to allow the color change to be readily observed from avantage point outside the composite material.

The color change elicited by the reagent may be in response to one ormore properties of the fluid that passed through the failed fluidimpermeable layer. Additionally, or alternatively, more than one reagentmay be associated with the intermediate layer 16, 160 and the reagentsmay individually react in various ways to indicate a particular type offluid that has passed through the failed layer. For example, the wetnessof the fluid may be indicated by a color change in one or more reagent.If a protein is present in the fluid, a reagent intended to detect theprotein may change color. If the fluid passing through a fluidimpermeable layer 12, 14, 120, 140 is expected to vary in pH, litmusmixture may be the reagent associated with the intermediate layer 16,160, to provide an indication of the type of fluid that has entered thecomposite material. Reagents capable of changing color based on pKavalues, the presence of fluids containing amino acids, proteins, urine,other bodily or biological fluids, or water may also be present in theintermediate layer 16, 160.

Reagents may include chemical indicators that change color as pHchanges. Acid/base indicators may be visible as a first color underneutral conditions and visible as a second, different color at an acidicor basic pH. Two examples, Bromocresol Green (also known as 3′, 3″, 5′,5″-tetrabromo-m-cresol-sulfonephthalein with a pK of 4.90) andBromophenol Blue are blue at a neutral pH and transition through greento yellow as the pH decreases. Bromocresol Green transitions between pHvalues of about 5.4-3.8. Bromophenol Blue transitions between pH valuesof about 4.6-3.0. Another example is Phenolphthalein which is clear at aneutral pH and transitions to red-violet at the pH increases.Phenolophthalein transitions between pH values of about 8.0 to about9.8. Other examples include, but are not limited to, litmus, NitrazineStrips, Bromothymol Blue, Methyl Orange, and Yamada Universal Indicator.

Reagents that appear as one color when dry and a second, different colorwhen wet can also be useful. For example, cobalt chloride is blue whendry and dark red when wet.

Reagents that luminesce may be desired if the composite material isintended for use in lower light settings. For example, some suitablechemiluminescence reagents may be diphenyl oxalate which, when combinedwith a weak base (e.g., 2,4,6-trichlorophenol) is responsible for theluminescence in a glow stick. Various colors may be produced dependingupon the dye added. Other examples include lunimol, and fluorescein.

As with any chemical reaction, there are generally multiple components.The various compounds can be considered as to which chemical is embeddedas a solid within the fabric, and which is suspended in the reactingfluid.

The reagent associated with the intermediate layer may be placed thereor be impregnated in a pattern. For example, the fluid impermeable layermay be transparent so that the color change of the pattern is visiblethrough one or both of the fluid impermeable layers after the fluidbreaches one of these layers. The pattern may be individual orinterlaced shapes or designs, or may be letters that spell out one ormore words to indicate a breach in one of the fluid permeable layers.

Rather than change color, the reagent may produce foam upon, or after,contact with a fluid. The foam may then be detectable in a number ofways including, but not limited to, causing a change in the thickness ofthe composite material. The change in thickness may be localized to thearea of material in which a breach of a fluid impermeable layer 12, 14,120, 140 or may generate a more generalized thickening of the material10, 100.

Further, the reagent associated with the intermediate layer 16, 160 mayrelease a fragrant substance when reacting to the fluid. The fragrantsubstance may exit the internal space 18, 180 of the composite material10, 100 through the breached area which could allow for detecting of thebreach of a fluid impermeable layer 12, 14, 120, 140 by detecting afragrance associated with the reaction between the fluid and thereagent.

Another example of a directly observable detection of a breach involvesconstructing the intermediate layer from a plurality of fibers having analterable characteristic, or including a plurality of such fibers in theintermediate layer. The fiber characteristic can be alterable aftercontact with a fluid. For example, the fibers may be color alterablehaving a first color prior to contact with the fluid and a second,different color after contact with the fluid. Additionally, oralternatively, the alterable characteristic may be size. For example,prior to contact with the fluid the fibers are not detectable by touch,but after contact with the fluid, the fibers may increase in size sothat they become detectable by touch.

As an alternative to, or in addition to, directly observable changes inthe intermediate layer upon breach of a fluid through a fluidimpermeable layer, another embodiment of the composite material includesone or more devices that allow detection of a breach in the material.For example, the intermediate layer may include a reagent that is adielectric in the dry state, but becomes an electrolyte operable toconduct an electric current in an electric circuit after contact withthe fluid. The reagent may be salt that will dissolve in the fluid anddisassociate into anions, or negatively charged ions, and cations, orpositively charged ions. The circuit further includes a power source,such as a battery cell, and a current sensor that detects the current inthe circuit when the conductivity of the reagent changes.

Referring now to FIGS. 4, and 5 the composite material 300 may includean indicator, such as a light emitting diode (“LED”) 320, capable ofindicating a breach of one of the fluid impermeable layers. Electricsource 340 is in electric contact with the intermediate layer 360. Theelectric source is a part of an electrical circuit 380 including amaterial having a variable conductivity. The material transitions from afirst state (e.g., non-conductive) to a second state (e.g. conductive)opposite the first state after the fluid breach of the material 300 andafter moisturizing the material. The change in state of the materialcompletes the circuit 380 as illustrated in FIG. 5. When the materialchanges states and completes the circuit, the LED 320 is powered tosignal the breach. For example, the circuit 380 is open in dry state andclosed in wet state. By way of example, the reagent or material ofvariable conductivity may include salts containing one or more ofsodium, potassium, magnesium, iron, ammonium, quaternary ammonium,calcium and one or more of chloride, acetate, carbonate, citrate,fluoride, nitrate, nitrite, sulfates, and phosphates. However, anysuitable salt may be used. In addition to composite materials 10, 100described earlier, the composite material 300 may also be used as thecover 200 surrounding the mattress M of FIG. 3.

It should be understood that the powered device need not be a light, butmay be any other device capable for signaling a breach. Other devicesmay signal by, but not be limited to, an audible signal by an indicatorcapable of producing sound upon the change in state of the switch.

In composite materials having an intermediate layer with a plurality ofoptical fibers with an alterable characteristic, the characteristic maybe a change in the total internal reflection properties of the fiberswhen moisture alters their optical properties. This change may then bedetected, calculated or observed, for example, by observing the lightextracted from the side walls of the fibers when the fibers arecontacted by a fluid that disrupts total internal reflection in thefibers.

In addition to, or as an alternative to, providing an observableindication of a breach of the composite material, the breach may bedetectable on inspection. For example, the reagent may be reactive to acleaning material applied to one of the fluid impermeable layers if abreach in the impermeable layer is present. The cleaning material may bewater or another cleaning material, such as ammonia solution, that isapplied to the fluid impermeable layer during a routine cleaning sessionor may be applied at any time an inspection of the material is desired.

Another example of breach detection by inspection of the material mayinclude providing at least one positive electrical terminal and at leastone negative electrical terminal associated with said intermediatelayer. During routine inspection, or when inspection is desired, thepositive and negative terminals can be connected to a detector. Thedetector may be, for example, an interrogator and may be operable todetermine a status of the material based on whether an electricalcurrent or other signal is measured by the detector. For example, if anelectrolyte of the intermediate layer is dissolved by a fluid, thedetector may sense an electrical current when the terminals areconnected to it. The detector may further be in communication with adisplay device and the status of the material may be indicated on thedisplay device. If the composite material is a pad for a mattress, or ifthe composite material is incorporated into a mattress, the status ofthe material may be periodically checked and displayed by firstcommunicating the status of the material to the mattress and thencommunicating the material status from the mattress to a bed havingmonitoring and display features. Alternatively, the material status maybe checked and communicated directly to a bed with monitoring anddisplay features such as those disclosed in U.S. patent application Ser.No. 13/836,813, titled “Inflatable mattress and control means” filed onMar. 15, 2013 and incorporated herein by reference in its entirety.Multiple layer composite materials may also be provided with integrateddevices for avoiding or safeguarding against a complete failure orbreach in the composite material. In those instances, the intermediatelayer may include a detector capable of directly indicating the statusof the material. The detector may be operable to communicate a status ofthe material. The status may be indicated as new, active, or change. Newstatus may indicate that the composite material has recently beeninstalled or placed for use. Active status may be used to indicate thatcomposite material is expected to be functioning properly and/or nobreach in a fluid impermeable layer is expected or detected. Changestatus may be used to indicate that the material should be replaced dueto time of use, level of use, or indicated breach of a fluid impermeablelayer. For example, a timer may be included in the composite material tomeasure the length of time the material has been in use. A maximum timemay be set for the use of the material and once the time limit isexceeded, the detector may signal for inspection, removal, orreplacement of the composite material.

Age or wear of the composite material may also be measured by one ormore sensors included in the intermediate layer. The sensors can be setto detect a threshold level of movement of the composite material. Thenumber of threshold movements may be sensed and counted by a counter.Once a maximum number of threshold movements has been detected, thecounter can communicate the event may be sent to a communicationscomponent, such as a radio frequency identification (“RFID”) tag, and/ordisplay device to indicate a status change. An example of a determininguse by age or wear may include providing pressure sensors in an array inthe intermediate layer and reading a pressure map as and indication ofwear and use. The use or wear may be detected by pressure sensing arrayincorporated into a flexible sheet within the composite material.Examples of pressure sensing sheets or mats are described U.S. patentapplication Ser. No. 14/019,089 filed Sep. 5, 2013, U.S. patentapplication Ser. No. 14/341,328 filed Jul. 25, 2014, and PCTInternational Application No. PCT/US2012/027402 filed Mar. 2, 2012, allincorporated by reference herein in their entirety.

Referring to FIG. 6, the device 480 may be embedded in, or otherwiseplaced in, the intermediate layer 460 of the multiple layer compositematerial 400. The intermediate layer 460 may be positioned between thefirst fluid impermeable layer 420 and second fluid impermeable layer asdescribed herein. The device 480 may be a clock, timer, vibrationsensor, motion detector, gyroscope, or hydrometer, for example, that isset or programmable to detect a particular number of time units,particular motion, or humidity level. The device 480 may communicatethrough a wire or cable 485 the count of time or movements to a receiver490. The receiver 490 may include a separate or integrated display 492to indicate the count and/or status of the composite material 400.

Similarly, if the composite material includes four layers, the device580 may be embedded or positioned as shown in FIG. 7. The compositematerial 500 may include a first outer impermeable layer 520, a secondouter impermeable layer 540, an inner fluid impermeable layer 560 withthe device 580, and an inner reinforcement layer 570. As with the device480, the device 580 may be a clock, timer, vibration sensor, motiondetector, gyroscope, or hydrometer, for example, that is set orprogrammable to detect a particular number of time units, particularmotion, or humidity level. The device 580 can communicate through a wireor cable 585 the count of time or movements to a receiver 590 anddisplay component 592 to indicate the count and/or status of thecomposite material 500.

The devices 480, 580 may alternatively, communicate with the receiver490, 590 wirelessly.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,”“upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are usedto assist in describing the invention based on the orientation of theembodiments shown in the illustrations. The use of directional termsshould not be interpreted to limit the invention to any specificorientation(s).

Methods

In operation, detection of a fluid breach in the composite materialsdescribed above can be accomplished by the method 600 shown in FIG. 8.At step 610, the method includes providing a first fluid impermeablelayer, at step 620 a second fluid impermeable layer is provided. Anintermediate layer with a breach detection component is sealed betweenthe first and second fluid impermeable layers at step 630, a failureoccurring in the first or second fluid impermeable layer and fluidpassing into the intermediate layer occurs at step 640, and the fluidreacts with the detection component at step 650. At step 650, thereaction is observed or measured as an indication of the fluid breach atstep 660. The fluid breach into the intermediate layer may be detectedwhile continuing to provide a fluid barrier presented by the intactsecond fluid impermeable layer.

Providing the breach detection component may include providing a reagentsuch as any of the reagents described herein including, but not limitedto: a color changeable reagent capable of changing color based on one ormore of: pKa values, the presence of fluids containing amino acids,proteins, urine, other bodily or biological fluids, or water. A breachdetection component may also include a material having variableconductivity, a reagent capable of foaming after contact with the fluid,fibers with properties that are altered after contact with a fluid,reagents that produce or release a fragrance after contact with thefluid, and devices for measuring the age or wear of the material.

The step of observing a change in the breach detection components mayinclude one or more of: observing a change in color of the reagentreacting with a fluid passing through the first fluid impermeable layer;observing the presence of a foam in the material after the reagentcontacts the fluid; detecting a fragrance after the reagent contacts thefluid; detecting a change in a characteristic of a fiber after contactwith the fluid; and reading a display device indicating the age and/orwear level of the material.

Breach detection methods may also include wiping the outer surface ofthe multiple layer material and then detecting a failure of the outerlayer. For example, the method 900 of FIG. 11 includes the step ofproviding a first fluid impermeable layer at step 910, providing asecond fluid impermeable layer at step 920, sealing an intermediatelayer with a breach detection component between the first and secondimpermeable layers at step 930, a failure occurring in one of the fluidimpermeable layers at step 940, providing a wipe that is at leastpartially saturated with a fluid, or applying a fluid to the wipe atstep 950, applying the wipe with the fluid to one of the fluidimpermeable layers at step 960, and detecting the failure by the fluidreacting with the breach detecting intermediate layer at step 970. Thefluid applied to the wipe may be water or an additional agent that isactive with the reagent in the intermediate layer to detect a breach inthe fluid impermeable layer.

Additional steps may be included as shown in the method 700 of FIG. 9.After step 710 where there is provided a first fluid impermeable layer,and step 720 where there is provided a second fluid impermeable layer,there may be provided an intermediate layer with a salt and electriccurrent source at step 730. A failure in the first or second fluidimpermeable layer at step 740 causes the salt to dissociate into cationsand anions at step 750, and conducts an electrical current in theelectric circuit 760. The electrical current then powers an indicator tosignal a fluid breach at step 780.

Further, a step 770 may be included to provide a switch operable to movebetween a first state and a second state, and powering a visible oraudible indicator of the fluid contact with the electrolyte in the firststate.

If the method includes the step of providing a detector as the breachdetection component, the detector may be, for example, an interrogatoror other device capable of sensing an electrical current when attachedto terminals extending from the composite materials. The terminals, forexample, can facilitate the flow of electric current in the presence ofan electrolyte.

The step of providing a detector may also be the step of providing atimer, and the method may further include the step of measuring a lengthof time the material has been in use.

Additionally, or alternatively, the step of providing a detector caninclude providing a motion sensor. The method, then, may further includethe steps of detecting a threshold level of movement of the material,associating the motion sensor with a counter, and counting a number ofthreshold level of movement of the material.

Once a set, or prescribed, number of threshold level movements iscounted, the method may further include the steps of providing acommunication component, communicating the number of threshold levels ofmovement to the communications component, and relaying the number ofthreshold level of movements to a display device.

For example, the method 800 shown in FIG. 10 includes the step ofproviding a first multiple layer composite material with a first fluidimpermeable layer, a second impermeable, and sealing between them anintermediate layer with a first counting system at step 810, monitoringthe counting system at step 820, observing a maximum number of unitscounted in the counting system at step 830, removing the first multiplelayer composite material step 840, and providing a second multiple layercomposite material with a first fluid impermeable layer, a second fluidimpermeable layer, and sealing between them an intermediate layer with asecond counting system at step 850.

Additional steps may be included, such as providing a display device forthe displaying of the number of threshold level movements at the displaydevice.

In order to facilitate the detecting, communicating, relaying anddisplaying steps, the method may also include providing a controllerconfigured to control these steps.

The composite material described herein may be manufactured orconstructed by the steps of providing a first fluid impermeable layer,providing a second fluid impermeable layer, providing an intermediatelayer having a breach detector therein, and sealing the intermediatelayer between the first and second fluid impermeable layers.

Construction or manufacturing methods for the composite material mayalso include the steps of providing a reagent as the breach detector,and further may include providing a material having variableconductivity as the breach detector or reagent.

If a material having variable conductivity is provided, the method ofconstructing or manufacturing the composite material may also includethe step of providing a power source and a current detector.

Additionally, or alternatively, the construction or manufacturing methodmay include the step of providing the intermediate layer that includesproviding an intermediate layer having fibers.

The above description is that of current embodiments of the invention.Various alterations and changes can be made without departing from thespirit and broader aspects of the invention as defined in the appendedclaims, which are to be interpreted in accordance with the principles ofpatent law including the doctrine of equivalents. This disclosure ispresented for illustrative purposes and should not be interpreted as anexhaustive description of all embodiments of the invention or to limitthe scope of the claims to the specific elements illustrated ordescribed in connection with these embodiments. For example, and withoutlimitation, any individual element(s) of the described invention may bereplaced by alternative elements that provide substantially similarfunctionality or otherwise provide adequate operation. This includes,for example, presently known alternative elements, such as those thatmight be currently known to one skilled in the art, and alternativeelements that may be developed in the future, such as those that oneskilled in the art might, upon development, recognize as an alternative.Further, the disclosed embodiments include a plurality of features thatare described in concert and that might cooperatively provide acollection of benefits. The present invention is not limited to onlythose embodiments that include all of these features or that provide allof the stated benefits, except to the extent otherwise expressly setforth in the issued claims. Any reference to claim elements in thesingular, for example, using the articles “a,” “an,” “the” or “said,” isnot to be construed as limiting the element to the singular.

1. A multiple layer composite material comprising: a first fluidimpermeable layer; a second fluid impermeable layer; an intermediatelayer sealed between said first and second impermeable layers; saidintermediate layer having a reagent; and said reagent active with afluid when the fluid contacts said reagent after passing through saidfirst or second fluid impermeable layer.
 2. The composite materialaccording to claim 1 wherein said first fluid impermeable layer istranslucent, and wherein said reagent is visibly detectable when thefluid contacts said reagent.
 3. The composite material according toclaim 1 wherein said reagent is a chemical reagent, said chemicalreagent having a first color prior to contact with the fluid and asecond color different from said first color after contact with thefluid, wherein said second color is visible through said firstimpermeable layer.
 4. The composite material according to claim 1wherein said reagent is a chemical reagent, said chemical reagentoperable to produce a foam after contact with the fluid.
 5. Thecomposite material according to claim 1 further comprising an electricalcircuit in fluid communication with said reagent; and wherein saidreagent is a material of variable conductivity operable to induce anelectrical current in said circuit after contact with the fluid.
 6. Thecomposite material according to claim 1 wherein said reagent is reactiveto a cleaning fluid applied to said first fluid permeable layer, saidreagent being reactive with water or a bodily fluid.
 7. The compositematerial according to claim 1 wherein said intermediate layer isimpregnated with a pattern of said reagent, wherein said first fluidimpermeable layer is translucent, and wherein said pattern is visiblethrough said first fluid impermeable layer after the fluid passesthrough the first fluid impermeable layer.
 8. The composite materialaccording to claim 1 wherein said intermediate layer is a fabricreinforced layer.
 9. The composite material according to claim 1 whereinthe composite comprises a mattress cover, a protective garment, a glove,a rain coat, a barrier on a handle, a barrier on a seat, or a pad.
 10. Amultiple layer material with breach detection properties, the materialcomprising: a first fluid impermeable layer; a second fluid impermeablelayer; an intermediate layer sealed between said first and second fluidimpermeable layers; said intermediate layer having a detector; and saiddetector indicating a status of the material.
 11. The material accordingto claim 10, wherein said detector is a timer measuring a length of timethe material has been in use.
 12. The material according to claim 10wherein said detector is a sensor detecting a threshold level ofmovement of said material, and wherein said sensor is associated with acounter operable to count a number of threshold level of movements ofsaid material.
 13. The material according to claim 12 wherein saidcounter is operable to communicate said number of threshold levels ofmovement to a communications component, and wherein said communicationscomponent is operable to relay said number of threshold level ofmovements to a display device.
 14. The material according to claim 12wherein said communications component is a radio frequencyidentification tag.
 15. The material according to claim 10 wherein saidstatus is one of new, active, or change.
 16. A method of detecting abreach in a composite material, the method comprising the steps of:providing a first fluid impermeable layer; providing a second fluidimpermeable layer; providing an intermediate layer; providing a breachdetection component in the intermediate layer; sealing the intermediatelayer between the first and second fluid impermeable layers; andobserving a change in the breach detection component after a fluidpasses through the first impermeable layer.
 17. The method according toclaim 16 wherein said step of providing the breach detection componentincludes providing a reagent.
 18. The method according to claim 17wherein said step of observing a change in the breach detectioncomponents includes observing the reagent reacting with a fluid passingthrough the first fluid impermeable layer.
 19. The method according toclaim 17 further comprising the steps of: providing a wipe; applying afluid to the wipe; and applying the wipe to the first fluid impermeablelayer.
 20. The method according to claim 16 wherein said step ofproviding a breach detection component includes providing a material ofvariable conductivity.
 21. The method according to claim 20 wherein themethod further comprises the steps of: providing a circuit in fluidcommunication with the material of variable conductivity; and inducingan electrical current in the circuit after contact of the material ofvariable conductivity with a fluid passing through the first fluidimpermeable layer.
 22. The method according to claim 16 wherein saidstep of providing the breach detection component includes providing afiber having alterable characteristics.
 23. The method according toclaim 16 wherein said step of providing a breach detection componentincludes providing a detector.